HACCP Generic Model for

Pineapple Jam

Introduction to “Freshtz”

Located in Industrial Zone, Ja-ela

15 years of history

Over 400 employees

Specialized in Fruit processing

Pineapple jam is the main product

Our Mission

Serve the local suppliers and our customers through engaging in reasonable business

Providing high quality product

Our Vision

To be a pioneer nutritive, safe and high quality, Jam

producer in Sri Laka

Why we need HACCP

Improve the safety of our products

Achieve our long term goals

Reduce wastage

Reduce cost of production

Increase consumer confidence

Develop company Brand

Hazard Analysis and Critical Control Point(HACCP) is an internationally recognizedsystem for reducing the risk of safety hazardsin food.

Implementing a HACCP System requires

Prerequisite Programs

HACCP Plans

WHAT IS HACCP???

con’t

Is a system for food safety and not for the quality

Is a tool to protect against biological, chemical and physical

hazards in the food product

Is designed to minimize, not eliminate, the risk of food safety

hazards

Is designed for each materials and procedures

Receiving and storage

Sanitation of premises and surrounding environment

Personal hygiene of employees

Water supply

Equipment handling and maintenance

Lighting and ventilation

Waste management

Pest control

Pre requisite programs

• Consists of personnel with specific knowledge and expertise with regard to, the product and process

• Members were selected from each part of the pineapple jam plant

• Conducted the necessary studies, supervised the implementation of the HACCP plan and maintained its performance.

HACCP TEAM

HACCP TEAM

Factory Name:- “Freshtz” Product (pvt) Ltd

Team Member Name Position HACCP Team Role

E.M.P.P. Ekanayaka Production executive Coordinator

T.S.M Thilakarathne Quality Executive Member

N.R Nanayakkara Marketing & Finance Executive Member

T.Gawshiga Engineer Member

W.M.K.I.Bandara Fruit reception manager Member

Barathy Muddiyappu Shift leader of cutting, washing & peeling

Member

M.Chageethana Shift leader of production & packaging

Member

Shashindhi Samarakoon Cleaning supervisor Member

Pabodha Kodagoda Labour Member

T.Thadshayani SLSI consultant Advisor

Full descriptions of the pineapple jam

• Important product characteristics - aw, pH, colour

• Ingredients-pineapple, sugar, pectin, citric acid, water

• How is product used - With bakery products as spread

• Packaging - In sterilized glass jars

• Shelf life - 8 months

• Where will product be sold-Super markets , retail shop

• Labeling instructions

• Special distribution control

Product details & its distribution

General consumer – All age groups except

children less than 5 years

Food industry – Hotels, Fast food outlets

Not recommended for the people with

diabetics

Intended use & consumers

Flow diagram for pineapple jams production

1. Perform a Hazard Analysis

2. Determine Critical Control Points

3. Determine the Critical Limits

4. Monitoring Procedures of CCPs

5. Corrective Actions

6. Verification Procedures

7. Record Keeping Procedures

The 7 HACCP Principles

The process of collecting and evaluating information on

biological hazards

chemical hazards

physical hazards

associated with the flow of the Jam production process

Hazard Analysis

Biological Hazards – bacteria like Salmonella spp,

E. coli, Clostridium perfringens,Staphylococcus aureus, Vibriocholerae, Yeast & Mold

Chemical Hazards –Herbicide, Nitrate,polyurethane resin, chlorine,Lubricant, Heavy metals in inkHg, Cr, chlorine

Physical Hazards –Sand, Wood, Rotten fruits,Stones, Leaves, Metal fragments,Glass particles

Hazard Analysis cont'd

Done for

Ingredients,

raw materials,

step in the process,

product storage ,

Distribution,

Hazard Analysis cont'd

This is a point where Biological contaminationChemical contaminationPhysical contamination

can occur where loss of control may result in unacceptable health risk.

These hazards will be eliminatedprevented reduced

to an acceptable level at each step in the jam production process

Critical Control Points

Decision tree Model

Critical Control Points cont'd

The boundaries that must be met to control a food safety hazard

These standards will be

Observable

Measurable

usually specified by using temperature and time

Critical Limits

All CCPs are used

a maximum or minimum value to which a biological, chemical or physical parameter must be controlled at a CCP to prevent to an acceptable level

Ex: temperature, time, visual appearance

Critical Limits cont’d

Critical Control Points, Critical Limits,employees practices,

will be monitored on a daily basis by the employees involved in Jam production

Observations will be made to compare what actually happens to the standards that have been established.

Monitoring Procedures of CCPs

Established if a Critical Limit has not been met at a Critical Control Point

It will address what needs to be done to eliminate or control the possible hazards

Corrective Action

Process/St

ep CCP

Hazard(s) Critical

Limit

Monitoring Procedure Corrective

ActionsWhat How Frequency Who

CCP # 1

Sterilization

of glass

bottles (P)

Broken Glass

particles

No

damaged

bottles

Damaged

bottles

Visual

observation

Every bottle Worker at

Sterilizatio

n machine

Remove the

damaged

bottle and

send to the

glass

recycling

CCP # 2

Pasteurizatio

n (B)

Clostridium

perfringens

0cfu/ml

Clostridium

perfringens

Pasteuriza

tion time

and

temperatu

re

Visual

observation

Once the

alarm of the

machine

sounds

Worker at

Pasteuriza

tion

machine

Hold the

pasteurizatio

n.

Call the

quality

assurance

executive.

Verification may be defined as activities other than monitoring, that determine validity of HACCP

Primary components

Critical control point verification.

HACCP system verification.

Validation.

Verification

Critical control point verificationCCP is backbone of the HACCPimportant to verified the all activities and procedures

HACCP system verificationit contains, activities that go beyond the written plan to it’s implementation

Validation collecting and evaluating scientific and technical information to determine whether HACCP is properly implemented

Verification cont’d

Important aspects

Check whether HACCP system is functioning according to written HACCP procedure

Initial validation of HACCP plan to determine that it is scientifically and technically tested

Verification procedure can be carried out by individuals within a company for each CCP

Verification cont’d

It is a process to maintain written documents for each verification procedure.

2 CCPs – 1. sterilization of glass bottles

There would be glass particles in machine-cause hazard.

2. pasteurization

There would be microbes called clostridium perfringens in

pasteurization machine- cause hazard.

Machine operation log is checked and commented on log book.

Record keeping

Process Step/CCP Verification Procedure Records

CCP# 1

Sterilization of glass

bottles (P)

Check the machine

operation log every day

comments on log book

CCP # 2

Pasteurization (B)

Check the machine

operation log every day

comments on log book

Introduction

What is HACCP?

Pre requisite programs

The 7 HACCP Principles 7 HACCP Principles

Summary